Industrial robot

ABSTRACT

A spot welding robot including a base and an arm assembly mounted on the base. The arm assembly includes a lower arm mounted at a lower end on the base for a swingable movement about a substantially horizontal first axis, a swingable member mounted on the lower arm at an upper end portion of the lower arm for a swingable movement about a second axis which is parallel with the first axis, and an upper arm mounted at one end portion on the swingable member for a swingable movement about a third axis which is perpendicular to the second axis. The swingable member has a portion extending in a direction opposite to the direction in which the upper arm extends. A driving motor is provided on the swingable member for driving the upper arm to produce the swingable movement of the upper arm about the third axis.

.[.This application.]. .Iadd.This is a continuation of application Ser.No. 08/112,470 filed Aug. 27, 1993, now abandoned, which in turn is aReissue of application Ser. No. 07/681,404 filed Apr 4, 1991 (U.S. Pat.No. 5,145,312), which in turn .Iaddend.is a continuation of applicationSer. No. 07/401,873, filed Sep. 1, 1989.Iadd., now abandoned.Iaddend..

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an industrial robot and moreparticularly to an industrial robot having at least three articulatedpivotal joints. The present invention can most suitably be applied to awelding robot for carrying out spot welding in a motor vehicle bodyassembling line but the invention is not limited to such an application.

2. Description of the Prior Art

In the motor vehicle industry, there is an increasing trend ofmanufacturing the vehicle body by welding thin steel sheets fordecreasing the body weight and providing the body with a requiredrigidity. Spot welding is commonly adopted for the purpose. Recenttendency is that the spot welding is made with finer spacings than usedto be so that number of spot welding is substantially increased. As anexample, approximately 5000 spot weldings are made in each one ofvehicle bodies. It is therefore unavoidably required in a vehicle bodyassembling line to provide a spot welding line of a substantialdistance. From the viewpoint of effective utilization of the factoryspace, however, it is advisable to make the spot welding line as shortas possible.

A typical example of spot welding robots adopted in vehicle bodymanufacturing lines is shown in FIGS. 10 and 11. As shown, the robotincludes a stationary base 1 supporting a swivel body 2 for swivelmovements about a vertical axis 3. One the swivel body 2, there ismounted a vertical swing arm 5 for fore-and-aft swinging movements abouta horizontal axis 6. On the upper end portion of the arm 5, there ismounted a horizontal swing arm 8 for vertical swing movements about ahorizontal axis 7. The horizontal arm 8 carries a hand 9 having weldingelectrodes at a tip end. A link 11 is provided to extend in parallelwith the arm 5 and connected at an upper end with a rearward end portionof the horizontal arm 8. The link 11 has a lower end which is connectedwith a horizontal link 11a which extends rearwardly from the axis 6 inparallel with the arm 8.

As shown in FIG. 11, the swivel body 2 is provided with a driving motor4 for driving the arm 5 about the axis 6. The arm 5 is swingable in thefore-and-aft direction through an angular range 82. The swivel body 2 isfurther provided with a driving motor 10 which is arranged to drive thelink 11a so that the link 11 is moved in a vertical direction to therebymake the horizontal arm 8 swing in the vertical direction through anangular range θ3. Appropriate operations of the motors 4 and 10 causeswinging movements of the arms 5 and 8 so that the robot hand 9 can bemoved in the region designated by the reference numeral 13.

This type of welding robot is considered as being advantageous in thatthe robot hand can be moved in a wide range with a relatively smallrobot body. It should however be noted that the welding robot of thistype still has a disadvantage which will be described below. In FIG. 10,the rearward end portion of the arm 8 is shown by the reference numeral12 when the arm 8 is in the horizontal position and by the referencenumeral 14 when the arm 8 is in the fully upwardly swung position. Itwill therefore be understood that the rearward end portion 14 of the arm8 projects by a distance R1 from the vertical axis 3 around which theswivel body 2 is rotated.

It will be noted that in this structure the rear end portion 14 of thearm 8 moves along a circular path of a radius R1 with a center at theaxis 3 when the robot is rotated about the axis 3. In a typical vehiclebody welding line, a plurality of robots 16 are arranged side by sidewith relatively small spacings between each adjacent two robots as shownin FIG. 12 at each side of a conveyor along which vehicle bodies 15 aremoved. The aforementioned movement of the rear end portion 14 of the arm8 may then cause an interference with the adjacent robot so that alarger spacing between each two adjacent robots must be provided foravoiding such possible interference.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide anindustrial robot which requires a smaller space than a conventionalrobot does.

Another object of the present invention is to provide an industrialrobot in which possibility of interference with a robot which is locatedto the first-mentioned robot can significantly be decreased.

According to the present invention, the above and other objects can beaccomplished by an industrial robot including an arm assembly having atleast a first arm and a second arm, each having a longitudinal axis,said first arm being mounted at a lower end portion on a base for aswingable movement in a substantially vertical plane about asubstantially horizontal first axis, said second arm being providedadjacent to an upper end portion of said first arm to extend in adirection crossing the longitudinal axis of said first arm, pivot meansprovided between said first and second arms for allowing swingablemovements of said second arm with respect to said first arm about asecond axis which is perpendicular to the longitudinal axis of saidfirst arm and a third axis which is in a plane containing thelongitudinal axis of said first arm, driving means for selectivelyeffecting said swingable movements of said first and second arms.

According to the features of the present invention, the pivot means isprovided for allowing a swingable movement about the third axis which isin a plane containing the longitudinal axis of the first arm and thepivot means is located above the first axis which is provided for theswingable movement of the first arm in a substantially vertical plane.It will therefore be understood that the rearward end portion of thesecond arm will be moved under the swingable movement about the thirdaxis along a circular path of a radius corresponding to a horizontaldistance between the pivot means and the rear end of the second arm andthis radius does not increase even when the first arm is fully inclinedrearward. Thus, the possibility of interference between the rear end ofthe second arm and an adjacent robot will significantly be decreased.

According to one aspect of the present invention, the second axis islocated below the third axis. For the purpose, a swingable member may beconnected to the upper end portion of the first arm for the swingablemovement about the second axis. The second arm is connected to theswingable member for the swingable movement about the third axis. Inthis arrangement, the swingable member is swingable in a substantiallyvertical plane and the third axis lies in this plane. In another aspectof the present invention, the third axis is located below the secondaxis. In this arrangement, a rotatable member may be provided in axialalignment with the longitudinal axis of the first arm for a rotationalmovement about the third axis which is in an axial alignment with thelongitudinal axis of the first arm. The second arm may then be connectedwith the rotatable member for the swingable movement about the secondaxis in a sideward direction.

The above and other objects and features of the present invention willbecome apparent from the following description of preferred embodimentstaking reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a spot welding robot in accordance with oneembodiment of the present invention;

FIG. 2 is a plan view of the robot shown in FIG. 1;

FIG. 3 is a sectional view taken substantially along the line A-B-C-D inFIG. 1;

FIG. 4 is a partially cut-away front view of a lower portion of therobot;

FIG. 5 is a partially cut-away side view of an upper portion of therobot;

FIG. 6 is a partially cut-away front view of the upper portion of therobot;

FIG. 7 is a plan view of the robot with the upper arm in a forwardlyshifted position;

FIG. 8 is a plan view of a vehicle body welding line showing an exampleof arrangement of the spot welding robot shown in FIGS. 1 through 7;

FIG. 9 is a schematical illustration of a spot welding robot inaccordance with another embodiment of the present invention;

FIG. 10 is a side view similar to FIG. 1 but showing a conventional spotwelding robot;

FIG. 11 is a perspective view of the conventional robot shown in FIG.10; and

FIG. 12 is a plan view of a vehicle body welding line showinginterference between two adjacent robots.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings, particularly to FIGS. 1 and 2, there is showna spot welding robot including a stationary base 20 supporting a lowerarm 22 for a swingable movement about a horizontal axis 21. The lowerarm 22 extends upwards from the base 20 and has an upper end on which anupper arm 24 is mounted. For mounting the upper arm 24 on the lower arm22, there in provided a swingable member or a mounting bracket 42.Referring to FIG. 6, it will be noted that the swingable member 42 has apair of stub shafts 42a provided at diametrically opposite positions andis mounted at the stub shafts 42a on the upper end portion of the lowerarm 22 for swingable movement about a horizontal axis 23.

As shown in FIG. 1, a link 39 is provided in parallel with the lower arm22. Referring to FIG. 4, it will be noted that the lower end of thelower arm 22 is mounted on the base 20 through a horizontal shaft 20awhich has an axis coaxial with the aforementioned axis 21. A horizontallink 38 is integrally connected at one end with the horizontal shaft20a. The other end of the horizontal link 38 is pivotally connectedthrough a pin 40 with the lower end of the link 39. The upper end of thelink 39 is pivotally connected through a pin 41 with the swingablemember 42 as shown in FIG. 1.

Referring to FIGS. 5 and 6, it will be noted that the upper arm 24 isformed at a rear end portion 54 with a stub shaft 54a which is extendingvertically downward and mounted through a bearing 54b on the upper endof the lower arm 22 for swingable movement about an axis 26 which isperpendicular to the axis 23. As shown in FIG. 1, the upper arm 24 isprovided at a front or tip end with a hand 55 which has weldingelectrodes.

In order to drive the lower arm 22 for effecting the swingable movement,the arm is provided at the lower end portion with a gear 43 as shown inFIG. 3. The gear 43 is in meshing engagement with a gear 80. A drivingmotor 81 is provided and has an output shaft 81a which is drivinglyconnected through a gear mechanism 82 with the gear 80. A selectiveoperation of the driving motor 81 will therefore produce a swingablemovement of the lower arm 22 throughout an angular range θ11 shown inFIG. 1.

Referring to FIGS. 3 and 4, it will be noted that the shaft 20a isprovided with a gear 36 which is rigidly secured to the shaft 20a. Amotor 27 is provided and has an output shaft 28 to which a driving gear29 is secured. An intermediate gear is provided on an intermediate shaft31 and is in meshing engagement with the driving gear 29. Theintermediate shaft 31 further has a gear 32 secured thereto. The gear 32on the intermediate shaft 31 is in meshing engagement with a gear 33provided on a second intermediate shaft 34. The second intermediateshaft 34 has a gear 35 which is in meshing engagement with the drivinggear 36 on the shaft 20a. It will be understood that the lower arm 22,the links 38 and 39 and the swingable member 42 provide a parallelogramso that a selective operation of the driving motor 27 causes a swingingmovement of the link 38 and a swinging movement of the member 42. Thus,the upper arm 24 is swingably moved through an angular range θ12 asshown in FIG. 1.

Referring now to FIGS. 5 and 6, it will be noted that a driving motor 25is provided on a rear end portion of the swingable member 42. The motor25 has an output shaft 46 which is provided with a pulley 46a. On theswingable member 42, there is further provided a pulley 48 which isdrivingly connected with the pulley 46a through a belt 47. Anintermediate pulley 49 is provided coaxially with the pulley 48 andconnected with this pulley 48 to rotate together. A driven pulley 51 isprovided at the lower end portion of the stub shaft 54a on the rear endportion 54 of the upper arm 24 and connected with the pulley 49 througha belt 50. It will therefore be understood that by a selective operationof the motor 25 the upper arm can be swingably moved about the axis 26through an angular range θ13 as shown in FIG. 2. FIG. 7 shows the upperarm 24 in a position swung leftward about the axis 26.

In the structure described above, the hand 55 on the tip end of theupper arm 24 can be moved throughout the range 56 as shown in FIGS. 1and 2 by selective operation of the driving motors 25, 27 and 81. By anoperation of the motor 81, the lower arm is moved to swing between aforwardly inclined position 57 and a rearwardly inclined position 58. Inthe rearwardly inclined position 58 of the lower arm 22, the swing axis26 is shifted rearwards to a position shown by reference 26a in FIG. 2.The rear end portion of the swingable member 42 is also shiftedrearwards to a position shown by a reference 42b. When the motor 25 isoperated with the lower arm 22 located in this rearwardly inclinedposition 58, the rear end portion 54 of the upper arm 24 will be movedalong a circular path having a center of the circle at the point 26a asshown by a reference 54b in FIG. 2.

In a conventional design, the horizontal swinging movement is producedabout a vertical axis which will not be shifted rearward even when thelower arm is inclined rearwards. Therefore, the upper arm 24 will beswingably moved about the axis 26 even when the lower arm is fullyinclined rearwards. Thus, the rear end portion 54 of the upper arm 24will be moved along a circular path 54c having a center of circle at thepoint 26 as shown in FIG. 2. The arrangement of the present invention isadvantageous over the conventional design in that the path of the rearend portion 54 of the upper arm 24 is much smaller than in theconventional design.

The illustrated structure is further advantageous in that the motor 25for driving the upper arm 24 is provided on the swingable member 42which is formed separately from the upper arm 24. In FIG. 2, it will benoted that the swingable member 42 will be shifted rearwards to theposition shown by 42b when the lower arm 2 is fully inclined rearwards.However, since the swingable member 42 is made separately from the upperarm 24, the rear end portion of the member 42 does not move when theupper arm 24 is swung about the axis 26a. According to the conventionaldesign, the upper arm is mounted on the upper end portion of the lowerarm and has a rearward extension to provide the aforementionedparallelogram. The rear end portion of the upper arm will therefore bemoved along a circular path 59 having a center of circle at the point 26shown in FIG. 2. The structure of the illustrated arrangement istherefore significantly advantageous over the conventional design indecreasing the space required for locating the robot.

In FIG. 8, there is shown a typical example of arranging the robots inaccordance with the present invention. As shown, vehicle bodies 60 to bewelded are transported along a conveyor 62. A plurality of robots 61 arearranged along the opposite sides of the conveyor 62. According to thepresent invention, it becomes possible to locate the robots with closespacings.

Referring now to FIG. 9, there is shown another embodiment of thepresent invention. The robot shown in FIG. 9 includes a stationary base63 supporting a lower arm 65 through a horizontal shaft 64 for aswingable movement. An intermediate arm 67 is connected with the lowerarm 65 through a swivel joint 66 so that the arm 67 is rotatable about alongitudinal axis of the lower arm 65. An upper arm 68 is connected toan upper end of the intermediate arm 67 for a swingable movement aboutan axis 71 which is perpendicular to the longitudinal axis of the lowerarm 65. The upper arm 68 is connected at a tip end with a second upperarm 70 through a swivel joint 69 for rotation about a longitudinal axisof the first upper axis 68.

The invention has thus been shown and described with reference tospecific structures, however, it should be noted that the invention isin no way limited to the details of the illustrated structures butchanges and modification may be made without departing from the scope ofthe appended claims.

We claim:
 1. An industrial robot including a base, a lower arm mountedat a lower end on said base for a swingable movement about asubstantially horizontal first axis, first motor means provided on saidbase for driving said lower arm to produce the swingable movement ofsaid lower arm about said first axis, a swingable member mounted on saidlower arm at an upper end portion of said lower arm for a swingablemovement about a second axis which is parallel with said first axis,second motor means provided on said base for driving said swingablemember to produce the swingable movement of said swingable member aboutsaid second axis, an upper arm mounted at one end portion on saidswingable member for a swingable movement about a third axis which isperpendicular to said second axis, said upper arm projecting in onedirection from said upper end portion of said lower arm and provided atthe other end portion with a robot hand, said swingable member having aportion extending in a direction opposite to said one direction beyondsaid one end portion of said upper arm, third motor means.Iadd.,.Iaddend.mounted on said portion of said swingable member .Iadd.andintersected by a plane defined by the swingable movement of said upperarm about said third axis, .Iaddend.for driving said upper arm toproduce the swingable movement of said upper arm about said third axis.2. The industrial robot of claim 1 in which said lower arm has alongitudinal axis and said horizontal first axis and said second axisare perpendicular to said longitudinal axis.
 3. The industrial robot ofclaim 1 including a link extending generally parallel to said lower armfor interconnecting said swingable member and said second motor means.4. The industrial robot of claim 1 in which said robot hand carrieswelding electrodes.
 5. The industrial robot of claim 1 in which saidrobot hand is mounted for pivotal movement in relation to said upperarm.
 6. The industrial robot of claim 1 in which said portion of theswingable member on which said third motor means is mounted is separatefrom said .[.swingable member.]. .Iadd.upper arm .Iaddend.and does notmove when the upper arm is moved about said third axis. .Iadd.
 7. Anindustrial robot including a base, a lower arm mounted at a lower end onsaid base for a swingable movement about a substantially horizontalfirst axis, first motor means provided on said base for driving saidlower arm to produce the swingable movement of said lower arm about saidfirst axis, a swingable member mounted on said lower arm at an upper endportion of said lower arm for a swingable movement about a second axiswhich is parallel with said first axis, second motor means provided onsaid base for driving said swingable member to produce the swingablemovement of said swingable member about said second axis, an upper armmounted at one end portion on said swingable member for a swingablemovement about a third axis which is perpendicular to said second axis,said upper arm projecting in one direction from said upper end portionof said lower arm and provided at the other end portion with a robothand, said lower arm, said swingable member and said upper armcomprising an arm assembly, said arm assembly having a portion extendingin a direction opposite to said one direction beyond said one endportion of said upper arm, third motor means, mounted on said portion ofsaid arm assembly and intersected by a plane defined by the swingablemovement of said upper arm about said third axis, for driving said upperarm to produce the swingable movement of said upper arm about said thirdaxis. .Iaddend..Iadd.
 8. An industrial robot including:a base; an armassembly including a lower arm mounted at a lower end portion on saidbase for a swingable movement about a substantially horizontal firstaxis; a swingable member mounted on said lower arm at an upper endportion of said lower arm for a swingable movement about a second axiswhich is parallel with said first axis; and an upper arm mounted at afirst end portion on said swingable member for a swingable movementabout a third axis which is perpendicular to said second axis andprovided at a second end portion with a robot hand, said upper armprojecting in one direction from said upper end portion of said lowerarm; first motor means for driving said lower arm to produce theswingable movement of said lower arm about said first axis; second motormeans for driving said swingable member to produce the swingablemovement of said swingable member about said second axis; and thirdmotor means, mounted on a portion of said arm assembly and intersectedby a plane defined by the swingable movement of said upper arm aboutsaid third axis, for driving said upper arm to produce the swingablemovement of said upper arm about said third axis, at least a portion ofsaid third motor means mounted on the arm assembly extending beyond saidsecond axis in a direction opposite to said one direction..Iaddend..Iadd.
 9. The industrial robot of claim 8, in which said secondand third axes intersect. .Iaddend..Iadd.10. The industrial robot ofclaim 8, in which said third motor means for driving said upper armabout said third axis is mounted on a portion of said arm assemblysituated above said lower arm. .Iaddend..Iadd.11. The industrial robotof claim 10, in which a longitudinal axis of said upper arm passesthrough said third motor means for driving said upper arm about saidthird axis. .Iaddend..Iadd.12. The industrial robot of claim 10, inwhich a longitudinal axis of said upper arm lies in a plane which passesthrough said third motor means for driving said upper arm about saidthird axis. .Iaddend..Iadd.13. The industrial robot of claim 8, in whichsaid portion of the arm assembly, on which is mounted said third motormeans for driving said upper arm, is fixed relative to said third axis,whereby the third motor means for driving said upper arm does not movewith said upper arm about said third axis. .Iaddend..Iadd.14. Anindustrial robot including:a base; an arm assembly including a lower armmounted at a lower end portion on said base for a swingable movementabout a substantially horizontal first axis; a swingable member mountedon said lower arm at an upper end portion of said lower arm for aswingable movement about a second axis which is parallel with said firstaxis; and an upper arm mounted at a first end portion on said swingablemember for a swingable movement about a third axis which isperpendicular to said second axis and provided at a second end portionwith a robot hand, said upper arm projecting in one direction from saidupper end portion of said lower arm; first motor means for driving saidlower arm to produce the swingable movement of said lower arm about saidfirst axis; second motor means for driving said swingable member toproduce the swingable movement of said swingable member about saidsecond axis; and third motor means, mounted on a portion of said armassembly and intersected by a plane defined by the swingable movement ofsaid upper arm about said third axis, for driving said upper arm toproduce the swingable movement of said upper arm about said third axis,said third motor means for driving said upper arm being positioned witha center of gravity thereof located beyond the second axis in adirection opposite to said one direction. .Iaddend..Iadd.15. Anindustrial robot including: a base; an arm assembly including a lowerarm mounted at a lower end portion on said base for a swingable movementabout a substantially horizontal first axis; a swingable member mountedon said lower arm at an upper end portion of said lower arm for aswingable movement about a second axis which is perpendicular to alongitudinal axis of said lower arm; and an upper arm mounted at a firstend portion on said swingable member for a swingable movement about athird axis which is perpendicular to said second axis, said upper armprojecting in one direction from said upper end portion of said lowerarm; first motor means for driving said lower arm to produce theswingable movement of said lower arm about said first axis; second motormeans for driving said swingable member to produce the swingablemovement of said swingable member about said second axis; and thirdmotor means, mounted on a portion of said swingable member extendingfrom said upper end portion of said lower arm in a direction opposite tosaid one direction, and intersected by a plane defined by the swingablemovement of said upper arm about said third axis, for driving said upperarm to produce the swingable movement of said upper arm about said thirdaxis. .Iaddend..Iadd.16. An industrial robot including:a base; an armassembly including a lower arm mounted at a lower end portion on saidbase for a swingable movement about a substantially horizontal firstaxis, and an upper arm assembly situated above the lower arm for aswingable movement about a second axis which is spaced from and parallelwith said first axis, the upper arm assembly comprising a first portionextending in one direction beyond the lower arm and a second portionextending in a direction opposite to said one direction beyond the lowerarm, said first portion being mounted for a swingable movement about athird axis which is perpendicular to said second axis; first motor meansfor driving said lower arm to produce the swingable movement of saidlower arm about said first axis; second motor means for driving saidupper arm assembly to produce the swingable movement of said upper armassembly about said second axis; and third motor means, mounted on saidsecond portion of said upper arm assembly and intersected by a planedefined by the swingable movement of said first portion of the upper armassembly about said third axis, for driving said first portion of theupper arm assembly to produce the swingable movement of said firstportion of the upper arm assembly about said third axis..Iaddend..Iadd.17. The industrial robot of claim 16, in which saidsecond portion of the upper arm assembly, on which is mounted said thirdmotor means for driving said first portion of the upper arm assembly, isfixed relative to said third axis, whereby the third motor means fordriving said first portion of the upper arm assembly does not move withsaid first portion about said third axis. .Iaddend..Iadd.18. Anindustrial robot including:a base; a lower arm mounted at a lower endportion on said base, and first motor means for swinging the lower armabout a first substantially horizontal axis; an arm assembly above saidlower arm including a swingable member mounted on an upper end portionof said lower arm for a swingable movement about a second axis which isparallel with said first axis, and an upper arm mounted at one endportion on said swingable member, said upper arm having a longitudinalaxis disposed above the upper end portion of said lower arm, and havinga robot hand at an opposite end portion thereof; second motor means forswinging said swingable member about said second axis; and third motormeans mounted on said arm assembly at said one end portion of said upperarm for swinging said upper arm about a third axis which isperpendicular to said second axis, said third motor means beingintersected by a plane defined by the swinging of said upper arm aboutsaid third axis. .Iaddend..Iadd.19. The industrial robot of claim 18,wherein the second and third axes intersect. .Iaddend.